Part 2
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ENGINE ASSEMBLY - HYBRID
Part 2
Continued From Part 1 Part 1
CAUTION: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley bolt. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.
CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages, coolant passages or the oil pan, can cause engine failure.
1. Turn the crankshaft clockwise to position the No. 1 piston at top dead center (TDC).
CAUTION: Failure to position the No. 1 piston at top dead center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.
37. Using the special tool, install a new crankshaft front oil seal.
NOTE: Remove the through bolt from the special tool.
NOTE: Lubricate the oil seal with clean engine oil.
38. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
NOTE: Do not install the crankshaft pulley bolt at this time.
NOTE: Apply clean engine oil on the seal area before installing.
39. Install a standard 6 mm (0.23 in) x 18 mm (0.7 in) bolt through the crankshaft pulley and thread it into the front cover.
CAUTION: Only hand-tighten the 6 mm (0.23 in) bolt or damage to the front cover can occur.
NOTE: This step will correctly align the crankshaft pulley to the crankshaft.
40. Assemble the special tools using 4 hardened washers in the location shown.
41. Install a new crankshaft pulley bolt. Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages:
- Stage 1: Tighten to 100 Nm {10.2 kgf-m, 74 ft-lbf}.
- Stage 2: Tighten an additional 90 degrees (1/4 turn).
CAUTION: The crankshaft must remain in the top dead center (TDC) position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the special tool and the bolt should be installed using hand tools only.
NOTE: Do not reuse the crankshaft pulley bolt.
42. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
43. Remove the special tool.
44. Remove the special tool.
45. Turn the crankshaft clockwise 1 and 3/4 turns.
NOTE: Only turn the engine in the normal direction of rotation.
46. Install the special tool.
47. Turn the crankshaft clockwise until the crankshaft contacts the special tool.
NOTE: Only turn the engine in the normal direction of rotation.
48. Using the 6 mm (0.23 in) x 18 mm (0.7 in) bolt, check the position of the crankshaft pulley.
- If it is not possible to install the bolt, the engine valve timing must be corrected.
CAUTION: Only hand-tighten the bolt or damage to the front cover can occur.
49. Install the special tool to check the position of the camshafts.
- If it is not possible to install the special tool, the engine valve timing must be corrected.
50. Remove the special tool.
51. Install a new crankshaft position (CKP) sensor and the 2 bolts.
- Do not tighten the bolts at this time.
NOTE: Whenever the crankshaft position (CKP) sensor is removed, a new one must be installed using the alignment tool supplied with the new part.
52. Adjust the CKP sensor with the alignment tool.
- Tighten the 2 CKP bolts to 7 Nm {0.7 kgf-m, 62 in-lbf}.
NOTE: The CKP sensor alignment tool is supplied with the new sensor and is not available separately.
53. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
54. Remove the special tool.
55. Install the engine plug bolt.
- Tighten to 20 Nm {2.0 kgf-m, 15 ft-lbf}.
56. Clean the valve cover gasket surface with metal surface cleaner.
CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.
57. Apply silicone gasket and sealant to the locations shown.
58. Install the valve cover.
- Tighten the bolts in the sequence shown to 10 Nm {1.0 kgf-m, 89 in-lbf}.
NOTE: The valve cover must be secured within 4 minutes of silicone gasket application. If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.
59. Install a new cylinder head temperature (CHT) sensor and the spark plugs.
- Tighten the CHT sensor to 12 Nm {1.2 kgf-m, 9 ft-lbf}.
- Tighten the spark plugs to 12 Nm {1.2 kgf-m, 9 ft-lbf}.
CAUTION: Only use hand tools when removing or installing the spark plugs or damage may occur to the cylinder head or spark plug.
60. Install the coil-on-plugs, bolts and the crankcase vent tube.
- Tighten to 8 Nm {0.8 kgf-m, 71 in-lbf}
NOTE: Apply dielectric compound to the inside of the coil-on-plug boots.
61. Install the 3 engine cover studs.
62. If equipped, install the block heater.
- Tighten to 21 Nm {2.1 kgf-m, 15 ft-lbf}.
63. Install the coolant hoses.
64. Install the oil filter adapter with a new gasket.
- Tighten to 25 Nm {2.5 kgf-m, 18 ft-lbf}.
NOTE: Clean the gasket mating surfaces with metal surface cleaner.
65. Install the crankcase vent oil separator and the knock sensor (KS).
- Tighten the oil separator bolts to 10 Nm {1.0 kgf-m, 89 in-lbf}.
- Tighten the KS to 20 Nm {2.0 kgf-m, 15 ft-lbf}.
66. Install the coolant hose.
67. Install the thermostat housing.
- Tighten to 10 Nm {1.0 kgf-m, 89 in-lbf}.
NOTE: Clean and inspect the thermostat housing gasket. Install a new gasket if necessary.
68. Install the coolant hose.
69. Install the coolant pump and bolts.
- Tighten to 10 Nm {1.0 kgf-m, 89 in-lbf}.
NOTE: Clean the coolant pump mating surface with metal surface cleaner.
NOTE: Lubricate the coolant pump O-ring with clean engine coolant.
70. Install the coolant pump pulley and bolts.
- Tighten to 20 Nm {2.0 kgf-m, 15 ft-lbf}.
71. Position the engine control wiring harness on the engine and connect the exhaust gas recirculation (EGR) valve electrical connector.
72. Connect the CHT sensor and install the rubber boot.
73. Connect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.
74. Install the fuel rail with the fuel injectors and the 2 stud bolts.
- Tighten to 23 Nm {2-3 kgf.m, 17 ft-lbf}.
75. Install the radio capacitor and the nut.
- Tighten to 10 Nm {1.0 kgf-m, 89 in-lbf}.
76. Install the EGR tube.
- Tighten to 55 Nm {5.5 kgf-m, 41 ft-lbf}.
77. Position the intake manifold and connect the PCV hose.
78. Install the intake manifold gasket and intake manifold and 8 bolts.
- Tighten to 18 Nm {1.8 kgf-m, 13 ft-lbf}.
NOTE: Inspect and install new manifold gaskets, if necessary.
79. Connect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.
80. Attach all the wire harness pin-type retainers to the intake manifold.
81. Connect the 4 fuel injector electrical connectors and the radio capacitor electrical connector.
82. Attach the pin-type retainer to the intake manifold and connect the KS electrical connector.
83. Connect the temperature manifold absolute pressure (TMAP) sensor electrical connector.
84. Connect the engine oil pressure (EOP) switch electrical connector.
85. Connect the evaporative emissions (EVAP) tube quick connect coupling to the intake manifold. See - Intake Air Distribution And Filtering.
86. Connect the lower coolant hose to the throttle body.
87. Connect the upper coolant hose to the throttle body.
88. Connect the throttle body electrical connector.
89. Install the oil level indicator tube and the 2 bolts.
- Tighten the lower bolt to 47 Nm {4.7 kgf-m, 35 ft-lbf}.
- Tighten the upper bolt to 10 Nm {1.0 kgf-m, 89 in-lbf}.
90. Install the accessory drive belt tensioner.
- Tighten to 25 Nm {2.5 kgf-m, 18 ft-lbf}.
91. Attach the engine wiring harness pin-type retainer.
92. Install the engine wiring harness connector bracket.
- Tighten to 15 Nm {1.5 kgf-m, 11 ft-lbf}.
93. Connect the CKP sensor electrical connector.
94. Using the heavy duty floor crane and spreader bar, remove the engine from the engine stand.
95. Install the flywheel and the bolts. Tighten the bolts in the sequence shown in the following 3 stages:
- Stage 1: Tighten to 50 Nm {5.0 kgf-m, 37 ft-lbf}.
- Stage 2: Tighten to 80 Nm {8.0 kgf-m, 59 ft-lbf}.
- Stage 3: Tighten to 112 Nm {11.2 kgf-m, 83 ft-lbf}.